Theoretical Analysis of IGAO-Fuzzy PID Fault-Tolerant Control and Performance Optimization for Electro-Hydraulic Active Suspensions Under Internal Leakage Faults

To address performance degradation and control instability in electro-hydraulic servo active suspension systems due to internal leakage faults arising from wear and aging of hydraulic components, this paper proposes an innovative fuzzy PID fault-tolerant controller based on the Improved Giant Armadillo Optimization (IGAO) algorithm. Specifically, to overcome the limitations of the standard Giant Armadillo Optimization (GAO), which is prone to local optima and exhibits poor convergence performance when handling multi-constraint parameter optimization problems, this study introduces a nonlinear dynamic inertia weight mechanism and a random reflection strategy for out-of-bounds particles to improve the original algorithm’s performance. These enhancements significantly enhance its ability to balance global exploration and local exploitation. Furthermore, this research develops a comprehensive performance evaluation fitness function by quantifying key performance indicators such as body acceleration, suspension dynamic deflection, and tire dynamic load. A quarter-car model incorporating an internal leakage fault was established as a simulation validation platform to demonstrate the reliability of the proposed method. Simulation results indicate that under various road excitation conditions, the proposed IGAO algorithm can rapidly and stably converge to superior parameters for the fuzzy PID controller. Compared to the Particle Swarm Optimization (PSO) and standard GAO algorithm, the control system optimized by IGAO not only significantly more effectively suppresses body vibration and reduces shock amplitude but also exhibits stronger dynamic recovery performance and control robustness under varying degrees of internal leakage faults. This research provides a robust control approach for addressing internal parameter uncertainties in hydraulic systems and offers a new approach to theoretical modeling for enhancing the reliability of design and fault-tolerant control capabilities of active suspension systems.